Engine - Knock From Front Of Vehicle

T-SB-0300-08

September 18, 2008

Abnormal Metallic Knock Noise from Front of Vehicle

Service Category
Drivetrain

Section
Hybrid Transmission/Transaxle

Market
USA





Applicability

Introduction

Some customers with 2004 - 2008 model year Prius vehicles may report a metallic knock or clunk noise from the engine bay heard only while driving over speed bumps or rough road conditions. The engine mount assembly has been improved to prevent this condition. Follow the repair procedure below to address customer concerns.

NOTE

The affected mount is attached to the hybrid transaxle. The part name in this service bulletin is "Insulator, Engine Mounting, LH" (left-hand). The Repair Manual also refers to this part as "Engine Mounting Bracket No.3".

Production Change Information





This TSB applies to vehicles produced BEFORE the Production Change Effective VINs shown.





Warranty Information

APPLICABLE WARRANTY

^ This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.


^ Warranty application is limited to correction of a problem based upon a customer's specific complaint.





Parts Information





Required Tools & Equipment

NOTE

Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.

Repair Procedure

After verifying that the "knock" noise is coming from the area near the hybrid transaxle replace the engine mounting insulator LH with a NEW part.

1. Remove the inverter w/converter assembly.

NOTE
Do NOT replace the inverter.

Refer to the Technical Information System (TIS) applicable model year Prius Repair Manual:

^ 2004 / 2005 Prius:
Engine/Hybrid System - Hybrid/Battery Control System - "W/converter Inverter Assy: Replacement"

^ 2006 / 2007 / 2008 Prius:
Engine/Hybrid System - Hybrid/Battery Control System - "P112 Hybrid Vehicle Control: Inverter With Converter: Removal"

2. Support the hybrid transaxle assembly by using a transmission jack.

3. Remove and replace the engine mounting insulator LH.





A. Remove the engine mounting insulator sub-assembly LH from the vehicle.





B. Remove two nuts from engine mounting insulator sub-assembly LH.





C. Replace the engine mounting insulator LH with the NEW part (P/N 12372-21111).

D. Tighten the 2 nuts.

Torque: 64 N*m (640 kg*cm, 47 ft*lbf)

E. Attach the engine mounting insulator sub-assembly LH on the vehicle.

Torque: 80 N*m (800 kg*cm, 59 ft*lbf)

4. Install the inverter w/converter assembly. Refer to TIS applicable model year Prius Repair Manual:

^ 2004 / 2005 Prius:
Engine/Hybrid System - Hybrid/Battery Control System - "W/converter Inverter Assy: Replacement"

^ 2006 / 2007 / 2008 Prius:

Engine/Hybrid System - Hybrid/Battery Control System - "P112 Hybrid Vehicle Control: Inverter With Converter: Installation"

5. Road test to verify proper operation of the vehicle.